Method of manufacturing axles and the like



1940- A. B. STEIGERWALT 2,212,903

METHOD OF MANUFACTURING AXLES AND THE LIKE Filed Sept. 20, 195'? 3 Sheets-Sheet -l F||3.1. Fuzz. Y

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METHOD OF MANUFACTURING AXLES AND THE LIKE Filed Sept. 20. 1937 3 Sheets-Sheet 2 FIEA.

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METHOD OF MANUFACTURING 'AXLES AND THE LIKE Filed Sept. 20. 1937 3 Sheets-Sheet 3 FIEL'7.

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Patented Aug. 27, 1940 k UNITED STATES METHOD OF MANUFACTURING AXLES AND- THE LIKE Albert B. Steigerwalt, Pittsburgh, Pa. Application September 20, 1937, Serial No. 164,807

4 Claims.

This invention relates to the production of metal shapes and, more particularly, to a method of die-forming such articles.

One object of this invention is to provide a method of producing a shaped metal article having homogeneous physical properties.

Another object of this invention is to produce an axle or the like which will be straighter and formed more nearly to the dimensions required of m the finished product.

Other objects and advantages will become apparent as the description proceeds, in which:

' Figure 1 is a front elevation of an apparatus which may be used to practice the method of the present invention;

Figure 2 is an end view of the apparatus, showing the relative position of the complementary die-members;

Figure 3 is an enlarged detailed sectional view of the guiding means on said die-members;

Figure 4 is an elevation, partly in section, of the upper die-member;

Figure 5 is a plan of Figure 4; b Figure 6 is an elevation of the lower die-mem- Figure 7 is a detailed elevation, showing the varying contours on the inner face of one of the die-members;

Figure 8 is a section on the line VIIIVIII of Figure 7;

Figure 9 is a section on the line IX-1X of Figure 7;

Figure 10 is a section on the line XX of Figure 7;

Figure 11 is a section on the line XIXI of 35 Fi re 7;

Figure 12 is a section on the line XlI--XII of Figure '7 I Figure 13 is a section on the line XIII-XIII of Figure 7; and

40 Figure 14 is an elevational view of the axle formed under the present invention. In the drawings, the numeral 2 represents a conventional type of die-press mill including hollow standards 3 for receiving the rams or 45 plungers 4 on the frame carrying the upper diemember 5. The lower die-member 6 is mounted, in any conventional manner, to the main body frame of said mill and is identical in construction with the die-member 5.

In order to insure that the body of metal from which the finished article is to be produced assumes the shape desired, the complementary diemembers 5 and 6 are provided with various contours, throughout their length, as shown in Fig- 65 ures 5 to 7 inclusive, in which it to be noted that the transverse contours of the faces of said complementary die-membersvary at the different sections. These contours are defined by a major radius 1 and minor radii 8, 9 and H], which are so designed and arranged along the die surfaces to develop in the body of "metal, under action of the press, a flow of metal downwardly and outwardly from a point midway of the 1ongitudinal axis of said body of metal toward each 9? end of said die-members.

' Throughout .the longitudinal length of said complementary die-members 5 and B, the contour varies from the central portion of said die-members toward each end thereof. In Figures 8 to 13 inclusive, a specific example is shown, in which the major radius may be, in Figure 8, 7 inches in diameter; in Figure 9, 6% inches in diameter; in Figure 10, 7 inches in diameter; in Figure 11, 7 inches in diameter; in Figure 12, 6

The

members 5 and 6, and for producing a finished k axle of the desired dimensions and taper without the necessity of subsequent machining.

The die-members, as shown, are designed primarily for the formation of railroad car axles but it is expressly understood that the die-members can be designed and arranged to produce differently. shaped articles of manufacture under the action of a press for causing the body of metal to fiow unrestricted toward the ends of the diemembers.

In order to obtain proper alignment of said die-members5 and 6, the body portion adjacent the ends of each die-member, is slotted to receive guide-brackets l2, the brackets on the bottom which will provide a force fit for the dowels l5. The upperdie-member 5 is provided with bores adapted. to receive bushings l6 within which the dowels I5 are adapted to slide when the upper die-member being bored at 14 to a diameter die member is moved downwardly to extrude the Y body of metal positioned within said die members for producing the product having the desired shape and contour.

In carrying out the method to be practiced. I under the present invention, as disclosed in the apparatus hereinbefore described, it is desirable that the body of metal to be extruded have a width approximately twice its thickness and a length approximately equal to the distance between the interior ends of the journal portions of the product axle and a volume not appreciably greater than that of the required finished axle. Under the present method of extruding the body of metal, it is possible to operate on a body of metal whose initial temperature is lower than that heretofore necessary. A satisfactory temperature of the body of metal being treated is approximately 1800 degrees Fahrenheit, and extrusion of a body of metal at such a temperature produces an axle having a finer grain characteristic and better physical properties throughout its length and cross-section. than is possessed by an axle finished at a higher temperature.

The hot body of metal is positioned in said lower die-member with its width in a vertical plane so as to subject the metal to the maximum amount of pressure when said upper die-member is moved downwardly upon its cooperating diemember 6. Such an action produces a maximum amount of equalized pressure upon said body of metal and results in the greatest possible longitudinal flow of the metal outwardly toward the open ends of said die-members with the minimum formation of flash or finning on the finished product. The diameter of the contour of the die-members is such that it is only slightly over the required size of the finished product and, as so constructed and arranged, requires only a minimum amount of finish turning and polishing to complete product.

The diameter of the contours along the face of the die-members is such that the portion indicated at A between the wheel-fits ll, with the included allowance for shrinkage, will produce an axle of the desired dimensions and degree of taper without the necessity of subsequent machining. Thus, the value of the tough surface skin, in withstanding the severe alternating.

stresses induced by the rotation of the axle, particularly in that portion of the axle immediately adjacent the inner edge of the wheel-fit I1, is preserved.

In order to provide for the minimum amount of finish turning and polishing of the journals I8, dust-guard seats !9 and wheel-fits H, the diameter of the die faces is made only slightly over size for these portions of the axle. By minimizing the cut necessary to be taken from the axle, it is possible to avoid tearing and weakening of the surface of the finished axle.

In the present method, the body of metal having the desired temperature, for example, approximately 1800 degrees Fahrenheit, having been positioned in the bottom die-member 6, pressure is then applied to said body of metal by downward movement of the upper die-member. This action will result in the extrusion of the body of hot metal over approximately '70 per cent of its surface and, upon additional pressures being applied through the upper die-member, the axle is formed. Prior to each subsequent pressure stroke of the upper die-member, the body of metal is rotated through a substantial angle by any conventional turning means (not shown) and thereby completely fiow said hot body of metal throughout the entire length of said diemembers so as to produce the resultant axle construction required.

A bull-dozer, of conventional design, is employed to form an upset flange portion 2!! on each of the outer ends of the journals 3. The axle journals H3 in particular having been formed of metal extruded along the longitudinal axis of the body of metal, will be free of seams and flaws, which defects are, at present, the most prevalent cause of rejection in finished axles. Axles produced by this method will be straight throughout their length, thereby eliminating the prior necessity of reheating and straightening. The axle will be symmetric and the various surfaces will be concentric with the longitudinal axis, while a minimum amount of metal may be removed by a uniform cut on the journals, dustguard seats and wheel-fits.

Under the present contour of the faces of the upper and lower die-members which cooperate with the body of hot metal having the desired proportions and volume, the entire journal portion of the axle is produced with extruded metal which has been caused to flow downwardly and outwardly, in a longitudinal direction, between the die-members simultaneously toward their open ends. Owing to the fact that under the present method it is possible to operate on a body of metal having a lower initial temperature than heretofore used, the finishing temperature is likewise lower; thus an axle is produced which has a finer grain and better physical properties.

While I have shown and described a specific embodiment of the present invention, it is to be understood that I do not wish to be limited exand the like which includes subjecting a metallic blank to the action of dies which are substantially longer than said blank, and extruding the metal of said blank longitudinally toward its ends, whereby the length of said blank is increased and substantially the entire journal portions of the axle are formed of metal which has been extruded outwardly toward the ends thereof. e

2. The method of producing metallic car axles 30 actly thereto, since various modifications may be and the like which includes subjecting a metallic blank to the action of dies which are substantially longer than said blank, and extruding all of the metal of said blank longitudinally toward its ends, whereby the length of said blank is increased and the entire journal portions of the axle are formed of metal which has been extruded outwardly toward the ends thereof.

3. The method of producing metallic car axles and the like which includes subjecting a metallic blank to the action of dies which are longer than said blank by an amount substantially equal to M the length of the journal portions to be formed, and extruding all of the metal of said blank longitudinally towards its ends, whereby the length of said blank is increased and substantially, the

entire journal portions of the axle are formed of metal which has been extruded outwardly toward the ends thereof.

4. The method of producing metallic ,car axles and the like which includes subjecting a metallic 7 blank to the action of dieswhichare longer than said blank by an amount equal to the length of the journal portions to be formed, and extruding the metal of said blank longitudinally toward its ends, whereby the length of said blank is in 

